Electrical-condenser manufacture



Nov. 30 Q 1926.

,c. HARDY.

ELECTBI CAL CONDENSER MANUFACTURE Filed Dec. 10, 1925 Patented Nov. 30, 1926.

UNITED STATES PATENT OFFICE.

CHARLES HARDY, NEW YORK, N. Y., ASSIGNOR TO AHSCO PRODUCTS, INC., 0] NEW YORK, N. Y., A CORPORATION OF NEW YORK.

ELECTRICAL-CONDENSER MANUFACTURE.

application filed December 10, 1925. Serial No. 74,471.

This invention relates to the manufacture of electrical condensers, and more particularly to the manufacture of variable air con densers; and has special reference to the provision of an lmproved variable air condenser" of the rotor and stator type and to improved methods of making the same.

The prime desideratum of my present invention centers about the production of improvements in the art of manufacturing electrical condensers, and more specifically in the provision of an improved method of manufacturing the rotor and stator sections of the condenser whereby the parts may be 16 effectively joined or united to ether by manufacturin steps which may iie carried out with rapi 'ty, facility and consequent economy of production, especially on a quantity production scale, to produce rotor and stator sections which are mechanically strong and durable and electrically eflicient in operation.

A more specific principal object of the invention relates to the efliclent manufacture of rotor and stator condenser sections in which 2 the condenser plates are joined to plate supporting blocks or members by a dovetailing interengagement of the arts and by uniting the interengaged rts y means of simple and easily carrie out riveting or swaging operations. A further prime object of my present invention comprehends the provislon of an improved method of joinin 0r uniting the stop or motion-limiting mem r usually forming part of the rotor section to the rotor section so that the same is immovably fixed or rigidly held against di lacement thereon, the method being carrie out with a minimum of manufacturing 0 rations.

To the accomplis ent of the foregoing and such other objects as may hereinafter appear, my invention consists in the elements and their relation one to the other, as hereinafter described and sought to be defined in the claims; reference being had to the accompanying drawings, which show the preferred embodiment of my invention, and in which:

Fig. 1 is a perspective view showing parts of the condenser rotor prior to assembly,

Fig. 2 is a perspective view showing the rotor parts in embryo assembled relation prior to the step of uniting the parts together,

Fig. 3 is a perspective view ofthe condenser rotor showing the same in completed assembled relation after the step of joining or uniting the parts together,

Fig. 4 is a perspective view of the condenser stator .in completed assembled relation,

Fig. 5 is a detail and enlarged view depicting the manner in which the plates of the condenser are joined or united to the plate supporting blocks of the condenser,

Fig. 6. is an enlarged'detail view thereof taken in cross-section in the plane of the line 66, Fig. 5,

Figs. 7, 8 and 9 are perspective views of sequential operations depicting the manner of joining a rotor stop member to the condenser rotor shaft, and

Fig. 10 is an enlarged detail view of a stator part showing the method of and means for uniting a stator plate to a plate supporting block.

Referring now more in detail to the drawings, and first havingreference to Figs. 1-3 and 5 thereof, I show the manner of making and assembling the rotor parts to form a rotor unit and employing certain principles of my present invention. As shown in Fig. 3 of the drawings, the assembled rotor unit comprises a shaft 10 having opposite ends 10' and 10 adapted to be journalled in end plates (not shown) of the condenser, the terminal of the shaft end 10 being preferably recessed as at 11 for receiving a ball bearing or the like, the said shaft 10 having an intermediate portion comprising a plate supporting block 12 which fixedly carries in s aced relation the plurality or set of con enser plates 13, 13, the said condenser plates being also held in spaced relation by means of a spacing member or strap 14 fixed to the condenser plates.

As heretofore mentioned, one of the prime objects of my present invention centers about the provision of an improved method of manufacturing the rotor section of the condenser whereby the parts may be effectively joined or united together by manufacturing steps which may be carried out with great rapidity, facility, and a consequent economy of production, especially on a quantity production scale, to produce a rotor section which is mechanically efficient.

To accomplish these and other ends, the plate supporting block 12 and the condenser plates 13, 13 are designed and constructed to be joined by a dove-tailing interengagement of the parts and to be ermanently united by a sim le operation of riveting or swaging the p ates onto the block. More particularly, the plate supporting block 12 is provided with a series of transverse grooves 15, 15 arranged longitudinally of the block, and each of the condenser plates 13 is cut or fashioned so as to be formed with a hub portion 16 provided with a cut-out 17 open at one side for receiving the block 12, the edge 17 and 17 of the cut-out defining tenon members receivable by the transverse grooves of the block with a dovetai ling interengagement, as clearly shown in Figs. 2 and 5 of the drawings. In the preferred form of construction, the transverse grooves 15 of the rotor plate supporting block 12 are out along three sides of the block to provide the set of grooves 15', 15 and 15 as shown particularly in Fig. 5 of the drawings, these grooves cooperating with the tenon edges 17' and 17 referred to, and with a third edge of the cut-out 17 designated as 17, the construction being such that the plates may be readily inserted or slipped onto the block with the grooves and tenon members in dovetailing interengagement, the grooves and tenon members being non-circular in crosssection whereby the plates-are held against rotation on the plate supporting block.

To efi'ect rapid and efficient permanent joining of the plates to the block, the block 12 is provided with one or more longitudinal faces such as 12 and 12 and the tenon members 17 and 17 of each plate are contoured or fashioned so as to have free ends designated respectively as 18 and. 18 which extend roximately beyond the said longitudinal b ock faces 12 and 12 when the plates are'mounted or assembled on the plate supporting block, as clearly shown in Figs. 2 and 5 of the drawings, the construction being such that the tenon ends may be readily flattened over the block faces by means of the light blow of a suitable blade-shaped hammer. Preferably the longitudinal faces 12' and 12 are arranged to intersect the tenon members at acute angles, as clearly portrayed in Fig. 5 of the drawings, so that a comparatively light blow of the hammer or forming tool is suificient to flatten, swage or rivet the tenon ends 18' and 18 over said faces, the faces acting as anvils in the swageriveting rocess. A comparison of Figs. 2 and 3 o the drawings shows the slight amount of extension of the tenon ends beyond the block faces which is necessary and the comparative ease with which the extending ends may be swaged or riveted over the inclined block faces, Fig. 2 showing the assembly prior to the swaging process and Fig. 3 showing the same subsequent to the swaging process. The effect of swaging the tenon ends is also indicated in Fig. 6 of the drawings, the said tenon ends 18' and 18 being there shown as flattened over the adjoining or contiguous block faces.

By means of this construction and mode of assembly, it will be seen that the plates may be readily mounted or assembled on the rotor shaft by simply inserting the tenon members in the socket forming grooves of the shaft block, the said plates being fixed against rotation on the shaft and arranged in parallel spaced relation; and that the said plates may be non-removably joined to the shaft block by subjecting the same to a simple swage-riveting step. In practice the condenser plates are arranged in a suitable form press in spaced relation, and the condenser shaft is inserted in the channel provided b the tenon members, after which a air of lade-shaped hammer members formmg part of the ress are moved into engagement with the ree tenon ends with a comparatively light impact or blow. After this operation, the embryo assembly may be subjected to a staking operation, whereby a plurality of indentations or dents such as 19, 19 are produced in opposite side walls of the shaft block 12, as shown in Figs. 3 and 6 of the drawings. This staking operation assists in malntaining the plates rigidly in spaced relation, although it is found that the dovetailing interengagement between the parts and the swage-riveting of thetenon ends are suilicient to stably maintain the plates in properly spaced relation.

The condenser plates 13 may obviously be made of any desired contour or configuration, and in the construction exemplified, these plates are shaped or formed to produce in cooperation with the stator section a straight-line frequenc calibration curve. The rotor plates are t erefore elongated in one direction and assume generally a heartshaped configuration; and with a late formation of this design, it is desirab e to provide additional means for maintaining the plates in spaced relation. To these ends, therefore, I provide the spacing strap -14 heretofore referred to, having a plurality of aligned perforations 20 which receive a plurahty o similarly aligned tea-ts or nibs 21,

21 formed integrally with the condenser lates 13, the said nlbs bein given a conguration so as to extend sli tly beyond the upper face of the strap 14 w en the same are received by the strap perforations 20, the construction being such that the extended ends can thereafter be swaged or riveted over the said face of the strap 14, as is clearly shown in Fig. 3 of the drawings, Fig. 2

showing the parts prior to the mounting of the s ac ing strap on the condenser plates, and ig. 3 showing the same after the nibs are swaged over the strap face. In the preferred construction, the strap 14 is arranged relatively to the plate supporting block 12 so that the riveting of the strap may be accomplished-simultaneously with the riveting of the tenon ends of the lates over the faces of the shaft block 12. is will be apparent from a consideration, for example, of Fig. 3 of the drawings, and it will be evident that the press may be rovided with three form ing elements whic are moved in one operation with a riveting impact on the parts to be joined together.

'Referring now to Figs. 4 and 10 of the drawings, I show some of the foregoing principles applied to the assembling of the stator section of the condenser, the said stator section comprising a plurality of stator plates 22, 22 adapted in the completed assembly to interleave with the plates 13 of the rotor, the said stator plates being spacedly mounted on a pair of plate supporting blocks 23 and 24 each having preferably an octagonal cross-sectional configuration similar to the rotor block 12, and each of these stator blocks is also slitted or cut transversely along the length of the block with a plurality of socket forming grooves 25, 25 for receivin the tenon members 26. 26 which are defined by the edges or walls of the cut-out 27 formed in each plate. In the stator structure, the blocks are grooved preferably at opposite walls thereof, and the cut-out 27 in each plate is contoured to accommodate or fit the grooved block, asclearly shown in Fig. 10 of the drawings. The free ends 28, 28 of the tenon members 26, 26 also extend proximately beyond longitudinal faces 29, 29

of a block such as 23 (see Fig. 10), and these ends may be swage-riveted over the block face, as shown in Figs. 4 and 10 of the drawings, in a manner similar to that heretofore described in connection with the rotor assembl As heretofore referred to, a further prime object of my present invention relates to the provision of an improved method of joining or uniting the stop or motion-limlting .member usually forming part of the rotor section to the rotor section so that the same is immovably fixed or rigidly held against d1splacement thereon. In preferred types of condenser structures, sto or motion-limiting means are usually provi ed to limit the rotation of the condenser rotor to a range of about 180, and such means customarily comprises a stop member fixed to the rotor shaft cooperating with a stop element mounted on a stationary part of the condenser assembly. In the adjustment of the condenser 1n use, the parts of the limiting means are ofttlmes caused to engage with a ar or blow which results in incremental displacements of the stop member on the rotor shaft or a loosening of such stop member, and as a consequence the range of condenser ad uStment is undesirably varied. The attachment or joining of these stop members to the rotor sections so that they may be permanentl fixed against displacementon the rotor sha t and function pro rl in use has been attended with consi erahle manufacturing difficulty, various operating steps being reuired to effect an eflicient union of the parts.

he present invention therefore contemplates the utilization of method stepsby means of which the disadvantages heretofore found in manufacturing practice are obviated and by which stop members are produced which are rmanently "oined against displacement. on t e rotor shaft.

The steps of the process by which the im'- proved results are achieved are depicted sequentially in Figs. 6-9 of the drawings, Fig. 6 showing the rotor shaft 10 construction prior to the attachment of the stop member thereto, Fig. 7 showingthe stop member in detached condition, and Figs. 8 and 9 show.- ing successive steps in joining the stop memher to the rotor shaft. Generically considered, the method of keying or aflixing the stop member to the rotor shaft consists in providing a stop member generally designated as 30, which when applied to the rotor shaft end 10 acts or serves as a cutting in-- strument 0} tool for cutting a portion of the shaft end in conformity with a shaft receiv-' ing opening 31 provided in the stop member.

More specifically, to accomplish the desired results the stop member 30, which is made of a metal harder than the shaft metal, is provided with the opening 31 which differs in cross-sectional configuration from that of a l shaft portion 32 having a dimension less than that of the block 12 but slightly greater than the shaft end 10 the reduced portion 32 and the block 12 defining an abutment shoulder 33. while the reduced portion 32 and the shaft end 10 define therebetween a flange portion 34, as shown particularly in Fig- 6 of the drawings. The shaft portion 32 is preferably circular, being turneddown in a lathe for sim licity of manufacture, and the shaft receiving opening 31 differs in configuration from the shaft portion 32 by the provision of one, and preferably a plurality of circumferentially disposed projections 35, 35 which define key elements, the said key elements functioning as cutting instruments for excising metal from the reduced shaft portion 32 to produce a plurality of key-ways 36, 36, as clearly shown in Fig. 8 of the drawings, when the stop memher 30 is forced onto the shaft and against the abutment shoulder 33.

Preferably the abutment shoulder 33 is chamfered to produce an annular channel 37, this channel serving as a depository or rece tacle for the metal cutfrom the shaft portion 32, as is shown at 38 in Fig. 9 of the drawings.

By means of this construction, it will be seen that the stop member 30 may be blanked or cut from sheet metal, and the same-forced onto the circular or cylindrical shaft in a suitable press, the mating keys and keyways being obtained during this step for roducin a sto member which is immova le and he (1 rigidly in position against rotation or other displacement on the condenser shaft. Although the metal of the shaft flportion 32 is spread during the operation su cientlyto hold the stop member30 against axial displacement on the shaft, it is preferred to swage the flange portion 34 over the ex osed face of the stop member 30, as clearly s own in Fig. 9 of the drawings, and in this way prevent axial as Well as rotatable displacement of the stop member. I

The method of manufacturing the condenser rotor and stator sections in accordance with the principles of my invention and the many advantages thereof and of the resulting condenser construction will in the main be fully apparent from the above detailed description thereof. It will be further apparent that numerous changes in the structural details or in the carrying out of the steps of the method may be made Without departing from the spirit of the invention. It will further be obvious that the steps of the method may be practiced in part for accomplishing the various advantages outlined, and that other of the steps may be applied more broadly in other relations. For example, it will be apparent that by reason'of the double plate supporting elements em-- ployed for the stator, it may suflice to unite the plates to the stator supports without the swage-riv'eting of the tenon members, and that the blocks or posts may be staked for accomplishing the desired end. It will also be obvious that the longitudinal faces of the plate supporting block may be arranged at any other angle than that shown in the preferred construction, the inclination or an-- gularity shown being preferred because the same permits of the swaging or riveting step being carried out with a minimum of'eifort in the operation of the riveting press.

. It will be also manifest that the tenon defining walls of the cut-out portions of the lates me. be given any desired contour, it

eing pre erred that the said contour be such that the plates are held non-rotatably in the statoror rotor plate supporting block. .It will be also obvious to those skilled in the art that the method of keying or joining the stop member to the rotor shaft is of general application, and that the steps 0f the method may be carried out in other, relations to unite a metallic member to a metal shaft circular in cross sectioii, all as defined in the appended claims.

I claim:

1. In. an electrical condenser, the combi nation of a plate supporting block and a set of condenser plates carried by and joined to the block comprising a plate supporting block having transverse grooves spaced longitudinally of the block, a plurality of condenser plates each formed with a cut-out open at one side for receiving the block, edges of said cut-out defining tenon members receivable by the transverse grooves of the block with a dovetailing interengagement, the free ends of said tenon members extending proximately beyond a longitudinal face of said block, the said tenon ends being flattened over said block face.

2. In an electrical condenser, the combination of a plate supporting block and a set of condenser plates carried by and joined to the block comprising sets of transverse grooves spaced longitudinally of the block, a plurality of condenser plates each formed with a cut-out open at one side for receiving the block, the said cut-out having a depth substantially equal to the thickness of the block, a plurality of edges of said cut-out defining tenon members receivable with a dovetailing interengagement by a set of transverse grooves in the block, the tenon members and grooves being non circular whereby the plates are held against rotation on the block, the said tenon members having ends at the open side of the cut-out which extend proximately beyond a longitudinal'face of said block, the said tenon grids being swage-riveted oversaid block ace. I

3. In an electrical condenser, the combination of a plate supportin block and a set of condenser plates carrie by and joined to the block comprising transverse grooves spaced longitudinally of'the block, a plurality of condenser plates eachformed with a cut-out open at one side for receiving the block, the edges of the-cut-oi'it defining tenon members receivable by the grooves of the block with a dovetailing interengagement, the said block having longitudinal faces intersectin the tenon members at acute angles and the rec ends of the saidtenon members extending proximately beyond said block faces, the said tenon members b'eing swageriveted over said block faces. 7

4. In an electrical condenser, in combination, a series of transverse grooves, a plurality of condenser plates formed to provide tenon members receivable by said grooves with a dovetailing interengagement, the said tenon members having free ends extending proximately beyond a longitudinal face of said block, the said tenon ends being flattened over said "block face, and a spacing member for holding'said plates in spaced relation consisting of astrip having perforations receiving nibs formed in said plates, the spacing member being secured to the plates by riveting the nibs over the spacing member.

5. In combination, a metal shaft and a.

metallic member keyed to the shaft, the said metallic member being made of a metal harder than the shaft metal and being rovided with a shaft receiving opening 1 ering in cross-sectional configuration from that of the shaft by the rovision of a means defining a key element, t 1e said shafthavin a key-way cut therein for mating with sa1 key element, said key-way being cut b the key element when said member is for onto the shaft.

6. In combination, a metal shaft and a :netallic member keyed to the shaft, the sa1d metallic member being made of a metal harder than the shaft metal and beingi rovided with a shaft receiving opening ering in cross-sectional configuratlon from that of the shaft by the provision of a plurality of circumferentially disposed projections defining key elements, the said shaft havin key-ways cut therein for mating with sai key elements, said key-ways being cut by the key elements by the forcing of said member onto the shaft.

7. In an electrical condenser, in combination, a metal condenser shaft and a metallic stop member keyed to the shaft, the said metallic stop member being made of a metal harder than the shaft metal and bein rovided with a shaft receiving opening i ering in CI'OSSzSGCtlODlil con ration fronithat of the shaft by the provision of a pro'ection defining a key element, the said sha having a key-way mating with said key element, sa1d ke -way being cut by the key element b the orcing of said stop member onto the s aft.

8. In combination, a metal shaft and a metallic member keyed to the shaft, said shaft having enlarged and reduced portions meeting in an abutment shoulder, the said metallic member being made of a metal harder than the shaft metal and being pro videdwith a shaft receiving opening differing in cross-sectional confi uration from that 4 of the reduced portion 0 the shaft by the provision of a means defining a key element,

'the said reduced shaft portion having a keyway out therein for mating with said key' element, said key-way being cut by the key element when said member is forced onto shaft by the provision of a means defininga key element, the said reduced shaft portion having a keyway cut therein for mating with said key element, said key-way being cut by the key element when said member is forced onto the shaft and against said abutment shoulder. I

10. In combination, a metal shaft and a metallic member keyed to the shaft, said shaft havmg enlarged and reduced portions meeting in an abutment shoulder, the said metallic member being made of a metal harder than the shaft metal and bein rovided with a shaft receiving opening 5i ering in cross-sectional configuration from that of the reduced portion of the shaft by the provision of a means defining a key element, the said reduced shaft portion havin a key-way cut therein for mating with sai key element, said' key-way being cut by the key element when said member is forced onto the shaft .and against said abutment shoulder, the outer end of said reduced shaft portion being swaged over said member.

11. In combination, a metal condenser shaft and a metallic stop member keyed to the shaft, said condenser shaft having enlarged and reduced portions meeti in a chamfered abutment shoulder, the sa1d metallic member being made of a metal harder than the shaft metal and being provided with a shaft receiving opening differing in cross-sectional configuration from'that of thevreduced portion of the shaft by the provision of a means defining a plurality of key elements, the said reduced shaft portion having key-waivs cut therein for mating with said keye ements, said key-ways being cut by the key elements when said member is forced onto the shaft and against said abutment shoulder, the cut metal being deposited in the chamfered shouldel, the outer end of said reduced shaft portion being. swaged over said stop member.

I 12. The method of making an electrical condenser which consists in producing a series of transverse grooves in a plate supporting block, in shaping condenser plates each with a cut-out open at one side so that the edges of the cut-out define tenon members, in assembling the plates on the block by dovetailin the tenon members with the coves, t e parts being fashioned so that Y e free ends of the tenon members roject proximately beyond a longitudinal ace of said block, in then riveting the free tenon ends on said block face, and in additionally holding said plates in spaced relationship by forming the lates with integral nibs, receiving the ni s in a spacing member provided with nib receiving perforations, and in riveting the nibs over and onto said spacing members.

13. The method of making .an electrical condenser which consists in producing a series of transverse. grooves in a plate supporting block, in s aping condenser plates each with a cut-out open at one side so that the edges of the cut-out define tenon members in assembling the plates on the block by dovetailing the tenon members with the grooves, the parts being fashioned so that ship' by forming the plates with integral nibs, recei the nibs in a spacin member provided wit nib receiving per orations, and in riveting the nibs over and onto said spacing members simultaneously with the riveting of the free tenon ends over the block face. I

14. The method of keying a metallic member to a metal shaft circular in cross-section which consists in cutting a shaft receiving opening in a metallic member made of metal harder than the shaft metal, the said openin havin a cross-sectional configuration difiering rom that of the shaft by the provision of a projection defining a key element, and in then forcing the member onto the shaft so that the edges of the key element act as a cutting tool to cut a keyway in the shaft for mating with said key element.

15. The method of keying a metallic member to a metal shaft circular in crosssection which consists in cutting a non-circular shaft receiving opening in a metallic member made of metal harder than the shaft metal. the said openin havin a lateral dimension smaller than t at of t e shaft,

and in then forcing the member onto the shaft so that the edges or walls of said 0 ning act as a cutting tool to cut the s aft metal to conform to the shape of said opening.

16. The method of keying a metallic member to a metal shaft circular in crosssection which consists in providing'a shaft receiving opening in a metallic member made of metal harder than the shaft metal,- the said openin havin a cross-sectional configuration di ering rom that of the shaft by the provision of a; plurality of circumferentially disposed projections defining keyelements, and in then forcing the member onto the shaft so that the key elements act as a cutting tool to cut mating key-ways in the shaft.

17. In electrical condenser manufacture, the method of keying a metallic stop memher to a metal condenser shaft which consists in cutting a shaft receiving openi in a metallic sto member made of the harder than the s aft metal, the said open: mg having a cross-sectional configuration di ering from that of the shaft by the provision of a projection defining a key element, and in then forcin the member onto the shaft so that the e ges of the key element act as a cutting tool to cut a key-way in the shaft for mating with said key element.

18. In electrical condenser manufacture, the method of keying a metallicstop member to a metal condenser shaft circular in -lining key elements, and in then forcin the member onto the shaft so that the sai key elements act as a cutting instrument to cut matin key-ways in the shaft. 7

19. he method of ke ing a metallic member 'to' a metal shaft w ich consists in cut- .the member onto the shaft so that the edges of the key element act as a cutting tool to cut a key-way in the shaft for mating with said key element.

Signed at New York city in the county of New York and State of New York, this 8th 0 day of December, A. D. 1925.

CHARLES HARDY. 

